Plastic layer pads are often used as separators and stabilizers when transporting products in palletized form. The materials that are used can vary; PP, HDPE, and PET are some examples. In this article, you will learn about the most common types of plastic layer pads and their applications.
1. What Are Plastic Layer Pads?
Plastic layer pads, or pallet layer sheets/separators sheets are layers which are placed on top of each product layer while stacking. Plastic layer pads provide stability, weight distribution, and prevent your products from moving during transportation. Unlike paper and cardboard, plastic layer pads are waterproof and durable.
2. Types of Plastic Layer Pads
Some of the common plastics used in the production of plastic layer pads are PP (polypropylene), HDPE (high-density polyethylene), and PET (polyethylene terephthalate). Out of these three plastics, PP is the most widely used.
1. PP Plastic Layer Pads
Polypropylene PP is one of the most common types of materials for plastic layer pads.
It has such features as lightness, strength, impact resistance, and moisture resistance.
Applications of PP layer pads:
PP layer pads can be used for:
- Glass bottles
- Aluminum cans
- Plastic bottles
- Food packaging
- Beverage packaging
- Buckets and pails
- Automotive industry components
- Other general packaging products.
PP corrugated sheets have fluted construction inside of the sheet. It allows achieving good stiffness with minimum weight of the sheet. If you are ordering large volumes of this product, this feature could be crucial for you because the decrease in weight of each sheet will reduce your handling and transportation costs.
2. HDPE Plastic Layer Pads
High density polyethylene (HDPE) is an advanced plastic layer that suits best for packaging and separation purposes. HDPE is characterized by high weight to strength ratio, toughness and moisture & chemicals resistant properties.
Applications of HDPE Plastic Layer Pads:
HDPE plastic layer pads can be used for:
- Chemicals packaging
- Industrial packaging
- Heavy items
- Food and beverages packaging
- Transportation of products within the reusable system
- Moisture exposed items
- Pallet separation
HDPE plastic layer pads can endure the impacts and harsh handling. They are especially useful if your logistics process consists of many trips, loads, unloads and harsh conditions.
HDPE is resistant to moisture as well. If you need to store and transport products in the humid environment, HDPE plastic layer pad will not absorb moisture unlike the cardboard.
3. PET Plastic Layer Pads
Polyethylene terephthalate (PET) offers high strength and rigidity.
PET is a good choice if you require a dimensionally stable material that can bear heavy pressure of the pallets stacked on top.
Applications PET Plastic Layer Pads:
PET layer pads can be used in situations like:
- Containing beverages
- Packaging glass materials
- Packaging food materials
- Industrial packaging applications
- Applications that require rigidity
While PET might not always be cost-effective, you should consider using it when rigidity and dimensional stability are your key requirements.
3. Applications of Plastic Layer Pads in Different Industries
It becomes much clearer if you take into account the application of the material.
l Beverage Industry
Layer pads for beverage producers and distributors may be used between bottles, cans, and other containers. It will help to create stable layers and prevent movement of products.
For example, in case of glass bottles, you need to use the correct layer pad in order not to let bottles have direct contact with each other and provide stability of the pallet..
l Food Industry
In the case of food and beverages, plastic layer pads will suit well due to their water-resistance and easier cleaning as compared to paper-based materials.
When choosing reusable layer pads, you have to think about the compatibility of the chosen material and product design with your cleaning needs.
l Chemical Industry
Packaging of chemical containers should provide high resistance to moisture and chemical agents. In some cases, HDPE and PP will fit well.
But you have to check the compatibility of the material with your products before selection.
l Industrial and Automotive Applications
Industrial or automotive products may be heavy or have an unusual shape. In addition, there can be rough transportation conditions. In such situations, you should use a plastic layer pad which will provide separation and protection between pallet layers.
You can consider HDPE and thick PP sheets for your application.
4. How Should You Choose the Right Plastic Layer Pad?
If you want to buy layer pads from abroad, take into account the following aspects:
Weight of the products to be shipped: Normally, heavier products would call for more durable and more rigid sheets.
Pallet size: The layer pad you select should be adapted to the size of the pallet and the arrangement of your products so that there is enough stability.
Environmental factors: Depending on whether your products get wet or cold, you will have to choose a material resistant to moisture.
Reuse: When reusability is a requirement, you will have to factor in durability, cleaning needs and life expectancy.
Thickness: With the increase in thickness, comes additional stiffness but also additional cost. Thickness will depend on your specific needs.
Sheet structure: Corrugated PP is great if you are looking for stiffness with lower weight, but for certain applications it will be better to use solid sheets.
Customization: In the case of large volume imports, you might need specific dimensions, colors, thickness, edges and even printing.
5. Frequently Asked Questions
Q1.Why does the surface finish of a plastic layer pad matter?
The reason is that the surface affects the friction, product mobility, cleaning, and the stability while stacking. A smooth surface can be easily cleaned, while a rough surface provides additional grip.
Q2.Are plastic layer pads better than cardboard pads?
Depends on your application. Plastic pads are usually more resistant to moisture and durable, but cardboard pads are less expensive for one-time use.
Q3.Does the pallet stacking pattern affect pad performance?
Yes. Various methods such as column stacking and interlocking have different weight distribution. The pad should therefore be chosen according to how you stack the products on the pallet.
Q4.What is the difference between virgin and recycled plastic layer pads?
Virgin plastic usually has more consistent material characteristics than recycled plastic, although recycled plastic is relatively cheaper and environment-friendly. It all depends on your need.
Q5.Are plastic layer pads suitable for high-speed packaging lines?
Yes. If designed appropriately, plastic layer pads may be employed in high-speed automatic packaging processes. Size, thickness, and surface characteristics are very important factors for consistent feeding into machines.
Q6.What is the difference between solid plastic layer pads and corrugated layer pads?
Solid plastic layer pads are stronger and more hygienic while also being moisture-resistant and durable. Corrugated layer pads are light in weight, cost-effective, recyclable, and can act as a cushion for your products.
6. Conclusion
Selecting the appropriate plastic layer pads is dependent upon your product, the size of the pallets used, weight of the load, mode of transportation, and budget. PP can be versatile, HDPE gives toughness, and PET gives rigidity. For further details on plastic layer pads, please visit PurePack.
